Clamp assembly for solar tracker

ABSTRACT

In an example, the solar tracker has a clamp assembly configured to pivot a torque tube. In an example, the assembly has a support structure configured as a frame having configured by a first and second anchoring region. In an example, the support structure is configured from a thickness of metal material. In an example, the support structure is configured in an upright manner, and has a major plane region. In an example, the assembly has a pivot device configured on the support structure, a torque tube suspending on the pivot device and aligned within an opening of the support, and configured to be normal to the plane region. In an example, the torque tube is configured on the pivot device to move about an arc in a first direction or in a second direction such that the first direction is in a direction opposite to the second direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is a continuation of U.S. application Ser. No.14/489,416 filed Sep. 17, 2014, which is a continuation in part of U.S.Ser. No. 14/101,273 filed Dec. 9, 2013, which claims priority U.S.Provisional Application No. 61/735,537 filed Dec. 10, 2012, each ofwhich is incorporated by reference herein for all purposes. The presentapplication also incorporates by reference, for all purposes, thefollowing concurrently filed patent applications, all commonly owned:U.S. Ser. No. 14/489,409 entitled OFF-SET DRIVE ASSEMBLY FOR SOLARTRACKER, filed Sep. 17, 2014, and U.S. Ser. No. 14/489,412 entitled OFFSET SWIVEL DRIVE ASSEMBLY FOR SOLAR TRACKER, filed Sep. 17, 2014.

BACKGROUND

The present application relates generally to a tracking system for solarpanels. More specifically, embodiments of the present invention providetracking systems that are suitable for solar panels. In a specificembodiment, a tracking system according to the present invention isfully adjustable in at each of the pillars, among other aspects. Thereare other embodiments as well.

As the population of the world increases, industrial expansion has leadto an equally large consumption of energy. Energy often comes fromfossil fuels, including coal and oil, hydroelectric plants, nuclearsources, and others. As an example, the International Energy Agencyprojects further increases in oil consumption, with developing nationssuch as China and India accounting for most of the increase. Almostevery element of our daily lives depends, in part, on oil, which isbecoming increasingly scarce. As time further progresses, an era of“cheap” and plentiful oil is coming to an end. Accordingly, other andalternative sources of energy have been developed.

Concurrent with oil, we have also relied upon other very useful sourcesof energy such as hydroelectric, nuclear, and the like to provide ourelectricity needs. As an example, most of our conventional electricityrequirements for home and business use come from turbines run on coal orother forms of fossil fuel, nuclear power generation plants, andhydroelectric plants, as well as other forms of renewable energy. Oftentimes, home and business use of electrical power has been stable andwidespread.

Most importantly, much if not all of the useful energy found on theEarth comes from our sun. Generally all common plant life on the Earthachieves life using photosynthesis processes from sun light. Fossilfuels such as oil were also developed from biological materials derivedfrom energy associated with the sun. For human beings including “sunworshipers,” sunlight has been essential. For life on the planet Earth,the sun has been our most important energy source and fuel for modernday solar energy.

Solar energy possesses many characteristics that are very desirable!Solar energy is renewable, clean, abundant, and often widespread.Certain technologies have been developed to capture solar energy,concentrate it, store it, and convert it into other useful forms ofenergy.

Solar panels have been developed to convert sunlight into energy. As anexample, solar thermal panels often convert electromagnetic radiationfrom the sun into thermal energy for heating homes, running certainindustrial processes, or driving high grade turbines to generateelectricity. As another example, solar photovoltaic panels convertsunlight directly into electricity for a variety of applications. Solarpanels are generally composed of an array of solar cells, which areinterconnected to each other. The cells are often arranged in seriesand/or parallel groups of cells in series. Accordingly, solar panelshave great potential to benefit our nation, security, and human users.They can even diversify our energy requirements and reduce the world'sdependence on oil and other potentially detrimental sources of energy.

Although solar panels have been used successfully for certainapplications, there are still limitations. Often, solar panels areunable to convert energy at their full potential due to the fact thatthe sun is often at an angle that is not optimum for the solar cells toreceive solar energy. In the past, various types of conventional solartracking mechanisms have been developed. Unfortunately, conventionalsolar tracking techniques are often inadequate. These and otherlimitations are described throughout the present specification, and maybe described in more detail below.

From the above, it is seen that techniques for improving solar systemsare highly desirable.

SUMMARY OF THE INVENTION

In an example, the present invention provides a clamp assembly for asolar module to be configured on a solar tracker system. As an example,the clamp has a thickness of rigid material. The clamp has a planarsurface region configured from a first portion of the thickness of rigidmaterial. In an example, the planar surface region has a length and awidth, although there may be variations. That is the planar surfaceregion can be slightly sloped, patterned, smooth, or otherconfigurations. In an example, the assembly has a saddle regionconfigured from a second portion of the thickness of rigid material. Inan example, the second portion is configured within an inner region ofthe planar surface region. In an example, the saddle region has a firstsurface and a second surface opposite of the first surface. In anexample, the second surface is shaped as a circular arc (or portion of acylinder) to be configured over a peripheral portion of a cylindricaltorque tube structure. In an example, the first surface has a heightco-planar with or slightly below a major surface of the planar surfaceregion, although there can be variations. In an example, the planarsurface region and the saddle region are formed from the thickness ofrigid material.

In an example, the saddle region comprises a key structure to beinserted into a notch structure configured on the peripheral portion ofthe cylindrical torque tube structure such that the key structure is amale portion to be inserted into a female portion of the notch structureto intimately connect the saddle region to the peripheral portion of thecylindrical torque tube structure. In an example, the key is aprotrusion that is fitted within the female portion.

In an example, the assembly has a first recessed region on a first sideof the saddle region and a second recessed region on a second side ofthe saddle region. In an example, the first recessed region is a mirrorimage of the second recessed region, while the saddle region is formedin between the pair of recessed regions. In an example, the assembly hasa first opening within the first recessed region and a second openingwithin the second recessed region. In an example, the first recessedregion has a slope configured from the saddle region to a first end ofthe planar surface region. In an example, the second recessed regionhaving a slope configured from the saddle region to a second end of theplanar surface region. In an example, the saddle region comprises afirst wider region within a vicinity of the first recessed region, and asecond wider region within a vicinity of the second recessed region.

In an example, the assembly has a U-bolt configured on a lower portionof the peripheral portion of the cylindrical torque tube structure suchthat a first bolt protrudes through the first opening and a second boltprotrudes through the second opening, and further comprises a firstfastener coupled to the first bolt and a second fastener coupled to thesecond bolt to secure the saddle region to the torque tube structure bysandwiching the torque tube structure between the second surface and abottom portion of the U-bolt.

In an example, the saddle region comprises a first wider region within avicinity of the first recessed region, and a second wider region withina vicinity of the second recessed region. A center region of the saddleregion is narrower, and each of the wider regions is symmetric with eachother. In an example, the first recessed region, the saddle region, andthe second recessed region are configured as an hour glass type shapewhen viewed from a spatial location normal to the planar surface region.

In an example, the thickness of rigid material comprises steel, such ascarbon hardened steel, or the like. In an example, the assembly has afirst border configured on a first edge of the planar surface region anda second border configured on second edge of the planar surface region.In an example, the assembly has a first border configured on a firstedge of the planar surface region and a second border configured onsecond edge of the planar surface region; and further comprising a pairof first openings within a vicinity of a first end of the planar surfaceregion and a pair of second openings within a vicinity of a second endof the planar surface region.

In other examples, the present invention provides a method of forming aclamp assembly for a solar module. The method includes providing athickness of rigid material. The method also includes forming a singlemonolithic structure comprising a planar surface region configured froma first portion of the formed thickness of rigid material, the planarsurface region having a length and a width; a saddle region configuredfrom a second portion of the formed thickness of rigid material, thesecond portion being configured within an inner region of the planarsurface region, the saddle region having a first surface and a secondsurface, the second surface shaped as a circular arc to be configuredover a peripheral portion of a cylindrical torque tube structure, thefirst surface having a height co-planar with or slightly below theplanar surface region.

In an example, the solar tracker has a clamp assembly that is configuredto pivot a torque tube. In an example, the assembly has a supportstructure configured as a frame having configured by a first anchoringregion and a second anchoring region. In an example, the supportstructure is configured from a thickness of metal material. In anexample, the support structure is configured in an upright manner, andhas a major plane region. In an example, the assembly has a pivot deviceconfigured on the support structure and a torque tube suspending on thepivot device and aligned within an opening of the support and configuredto be normal to the plane region. In an example, the torque tube isconfigured on the pivot device to move about an arc in a first directionor in a second direction such that the first direction is in a directionopposite to the second direction.

In an example, the present invention provides a solar tracker apparatus.In an example, the apparatus comprises a center of mass with anadjustable hanger assembly configured with a clam shell clamp assemblyon the adjustable hanger assembly and a cylindrical torque tubecomprising a plurality of torque tubes configured together in acontinuous length from a first end to a second end such that the centerof mass is aligned with a center of rotation of the cylindrical torquetubes to reduce a load of a drive motor operably coupled to thecylindrical torque tube. Further details of the present example, amongothers, can be found throughout the present specification and moreparticularly below.

Various additional objects, features and advantages of the presentinvention can be more fully appreciated with reference to the detaileddescription and accompanying drawings that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified perspective view of a horizontal trackerapparatus configured with a plurality of solar modules according to anembodiment of the present invention.

FIGS. 2 through 7 illustrate a method of assembling the horizontaltracker apparatus of FIG. 1.

FIG. 8 is a simplified perspective view of a pair of horizontal trackerapparatus configured together with a plurality of solar panels accordingto an embodiment of the present invention.

FIG. 9 is a simplified diagram of a plurality of horizontal trackerapparatus configured together according to an embodiment of the presentinvention.

FIG. 10 is a simplified diagram of an array of a plurality of horizontaltracker apparatus configured together according to an embodiment of thepresent invention.

FIG. 11 is a simplified diagram of a clamp assembly for the horizontaltracker of FIG. 1 according to an embodiment of the present invention;

FIGS. 12 through 14 are simplified diagrams illustrating a method forassembling the clamp assembly of FIG. 11.

FIG. 15 is a simplified perspective diagram of a drive assemblyconfigured on a pier member according to an embodiment of the presentinvention.

FIGS. 16 through 19 are simplified diagrams illustrating a method forassembling the drive assembly of FIG. 15.

FIG. 20 is a simplified in-line view diagram illustrating a clampassembly separate and apart from a pier member according to anembodiment of the present invention.

FIG. 21 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member according to an embodiment of thepresent invention.

FIG. 22 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member in a first orientation according to anembodiment of the present invention.

FIG. 23 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member in a second orientation according toan embodiment of the present invention.

FIG. 24 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a first orientation according to anembodiment of the present invention.

FIG. 25 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a second orientation according to anembodiment of the present invention.

FIG. 26 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a third orientation according to anembodiment of the present invention.

FIG. 27 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a fourth orientation according to anembodiment of the present invention.

FIG. 28 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a fifth orientation according to anembodiment of the present invention.

FIG. 29 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a sixth orientation according to anembodiment of the present invention.

FIGS. 30 through 32 illustrate an in-line view of the clamp assembly andthe drive assembly in multiple configurations according to embodimentsof the present invention.

FIG. 33 is a side view diagram of the tracker apparatus according to anembodiment of the present invention.

FIGS. 34 and 35 are simplified side view diagrams of a torque tubeaccording to an embodiment of the present invention.

FIGS. 36, 37, and 38 are simplified perspective-view, side view, andfront view diagrams of a clamp member according to an embodiment of thepresent invention.

FIGS. 39 and 40 are simplified perspective-view and side view diagramsof a clamp housing according to an embodiment of the present invention.

FIGS. 41, 42, 43, and 44 are simplified diagrams of component(s) for aU-bolt member according to an embodiment of the present invention.

FIGS. 45, 46, and 47 are simplified diagrams illustrating a method ofconfiguring a U-bolt member to a torque tube according to an embodimentof the present invention.

FIGS. 48 and 49 illustrate various views of a tracker apparatusaccording to an embodiment of the present invention.

FIGS. 50 and 51 illustrate views of a tracker apparatus according to anembodiment of the present invention.

FIGS. 52 and 53 illustrate an illustration of a torque tube according toan embodiment of the present invention.

FIG. 54 is a front view diagram of a clamp assembly according to anexample of the present invention.

FIG. 55 is a front view diagram of a clamp assembly in a stop positionaccording to an example of the present invention.

FIGS. 55A, 55B, 55C, 55D, and 55E illustrates various views of the clampassembly including a perspective view in a central position, aperspective view in a first stop position, a perspective view in asecond stop position, a side-view, and a top view in examples of thepresent invention.

FIG. 56 is a perspective view of a frame structure to be configured forthe clamp assembly according to an example of the present invention.

FIG. 57 illustrates a top view diagram, a front view diagram, and a sideview diagram of the frame structure to be configured for the clampassembly according to an example of the present invention.

FIG. 58 illustrates a top view diagram, a front-view diagram, and a sideview diagram of a U-bolt configured on a torque tube for a solar panelbracket according to an example of the present invention.

FIG. 59 illustrates a front view diagram of the U-bolt configured to atorque tube for a solar panel bracket according to an example of thepresent invention.

FIG. 60 illustrate a perspective view of a support member for the U-boltconfigured to a torque tube for a solar panel bracket according to anexample of the present invention.

FIG. 61 is a perspective view of a claim assembly according to anexample of the present invention.

FIG. 62 is a top view diagram of a clamp assembly according to anexample of the present invention.

FIG. 63 is a front view diagram of a clamp assembly according to anexample of the present invention.

FIG. 64 is a side view diagram of a clamp assembly according to anexample of the present invention.

FIG. 65 illustrates a top view diagram of a frame structure to beconfigured for the clamp assembly according to an example of the presentinvention.

FIG. 66 illustrates a front view diagram of a frame structure to beconfigured for the clamp assembly according to an example of the presentinvention.

FIG. 67 illustrates a side view diagram of a frame structure to beconfigured for the clamp assembly according to an example of the presentinvention.

FIG. 68 is a perspective view of a frame structure to be configured forthe clamp assembly according to an example of the present invention.

FIG. 69 is a perspective view of a claim assembly on a pier structureaccording to an example of the present invention.

FIG. 70 is a top view diagram of a clamp assembly on a pier structureaccording to an example of the present invention.

FIG. 71 is a front view diagram of a clamp assembly on a pier structureaccording to an example of the present invention.

FIG. 72 is a side view diagram of a clamp assembly on a pier structureaccording to an example of the present invention.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

The present application relates generally to a tracking system for solarpanels. More specifically, embodiments of the present invention providetracking systems that are suitable for solar panels. In a specificembodiment, a tracking system according to the present invention isfully adjustable in at each of the pillars, among other aspects. Thereare other embodiments as well.

In a specific embodiment, the present invention provides a trackerapparatus for solar modules. The tracker apparatus has a first piercomprising a first pivot device and a second pier comprising a drivemount. The drive mount is capable for construction tolerances in atleast three-axis, and is configured to a drive device. The drive devicehas an off-set clamp device coupled to a cylindrical bearing devicecoupled to a clamp member. The apparatus has a cylindrical torque tubeoperably disposed on the first pier and the second pier. The cylindricaltorque tube comprises a first end and a second end, and a notch. Thenotch is one of a plurality of notches spatially disposed along a lengthof the cylindrical torque tube. The apparatus has a clamp configuredaround an annular portion of the cylindrical torque tube and mate withthe notch to prevent movement of the clamp. The clamp comprises asupport region configured to support a portion of a solar module.

In an alternative embodiment, the present invention provides analternative solar tracker apparatus. The apparatus has a drive device, acrank coupled to the drive device and configured in an offset manner toa frame assembly. The frame assembly is coupled to a plurality of solarmodules.

In an example, the apparatus has a continuous torque tube spatiallydisposed from a first region to a second region. The crank comprises afirst crank coupled to a first side of the drive device and a secondcrank coupled to a second side of the drive device. The crank comprisesa first crank coupled to a first side of the drive device and a secondcrank coupled to a second side of the drive device; and furthercomprises a first torque tube coupled to the first crank and a secondtorque tube coupled to the second crank. The crank comprises a firstcrank coupled to a first side of the drive device and a second crankcoupled to a second side of the drive device; and further comprises afirst torque tube coupled to the first crank and a second torque tubecoupled to the second crank, and further comprises a first swage fittingcoupling the first crank to the first torque tube and a second swagefitting coupling the second crank to the second torque tube. Theapparatus also has a pier coupled to the drive device. In an example,the apparatus also has a drive mount coupled to a pier.

In an alternative embodiment, the present invention provides analternative solar tracker apparatus. The apparatus has a center of masswith an adjustable hanger assembly configured with a clam shell clampassembly on the adjustable hanger assembly and a cylindrical torque tubecomprising a plurality of torque tubes configured together in acontinuous length from a first end to a second end such that the centerof mass is aligned with a center of rotation of the cylindrical torquetubes to reduce a load of a drive motor operably coupled to thecylindrical torque tube.

In an example, the drive motor is operable to move the torque tube aboutthe center of rotation and is substantially free from a load. The centerof rotation is offset from a center of the cylindrical torque tube.

In an alternative embodiment, the present invention provides a solartracker apparatus. The apparatus has a clamp housing member configuredin a upright direction. The clamp housing member comprises a lowerregion and an upper region. The lower region is coupled to a pierstructure, and the upper region comprises a spherical bearing device.The upright direction is away from a direction of gravity. The apparatushas a clam shell clamp member coupled to the cylindrical bearing and atorque tube coupled to the spherical bearing to support the torque tubefrom the upper region of the clamp housing member. The torque tube isconfigured from an off-set position from a center region of rotation.

In an example, the apparatus is configured substantially free from anywelds during assembly. Reduced welding lowers cost, improvesinstallation time, avoids errors in installation, improvesmanufacturability, and reduces component count through standardizedparts. The torque tube is coupled to another torque tube via a swagedevice within a vicinity of the clam shall clamp member. In an example,the connection is low cost, and provides for strong axial and torsionalloading. The apparatus is quick to install with the pokey-yoke design.The torque tube is coupled to an elastomeric damper in line to dampentorque movement to be substantially free from formation of a harmonicwaveform along any portion of a plurality of solar panels configured tothe torque tube. The apparatus also has a locking damper or rigidstructure to configure a solar panel coupled to the torque tube in afixed tilt position to prevent damage to stopper and lock into afoundation-in a position that is substantially free from fluttering inan environment with high movement of air. The apparatus furthercomprises a controller apparatus configured in an inserter box providedin an underground region to protect the controller apparatus. Theapparatus has a drive device to linearly actuate the torque tube. In anexample, the apparatus uses an electrical connection coupled to a drivedevice. In an example, the spherical bearing allows for a constructiontolerance, tracker movement, and acts as a bonding path of leastresistance taking an electrical current to ground. The apparatus can beone of a plurality of tracker apparatus configured in an array within ageographic region. Each of the plurality of tracker apparatus is drivenindependently of each other to cause each row to stow independently at adifferent or similar angle.

Still further, the present invention provides a tracker apparatuscomprising a clam shell apparatus, which has a first member operablycoupled to a second member to hold a torque tube in place.

In an example, the apparatus also has a clamp housing operably coupledto the clam shell apparatus via a spherical bearing device such that thespherical bearing comprises an axis of rotation. The axis of rotation isdifferent from a center of the torque tube. The apparatus furthercomprises a solar module coupled to the torque tube.

In an example, the invention provides a tracker apparatus comprising aplurality of torque tubes comprising a first torque tube coupled to asecond torque tube coupled to an Nth torque tube, whereupon N is aninteger greater than 2. Each pair of torque tubes is coupled to eachother free from any welds.

In an example, each pair of torque tubes is swaged fitted together. Eachof the torque tubes is cylindrical in shape. Each of the plurality oftorque tubes is characterized by a length greater than 80 meters. Eachof the torque tubes comprises a plurality of notches. In an example, theapparatus also has a plurality of U-bolt devices coupled respectively tothe plurality of notches. Each of the plurality of torque tubes are madeof steel.

In an alternative embodiment, the present invention provides a trackerapparatus having a pier member comprising a lower region and an upperregion. A clamp holding member is configured to the upper region and iscapable of moving in at least a first direction, a second directionopposite to the first direction, a third direction normal to the firstdirection and the second direction, a fourth direction opposite of thethird direction, a fifth direction normal to the first direction, thesecond direction, the third direction, and the fourth direction, and asixth direction opposite of the fifth direction.

In yet an alternative embodiment, the present invention provides a solartracker apparatus. The apparatus has a clamp housing member configuredin a upright direction. The clamp housing member comprises a lowerregion and an upper region. The lower region is coupled to a pierstructure. The upper region comprises a spherical bearing device. Theupright direction is away from a direction of gravity. The apparatus hasa clam shell clamp member coupled to the cylindrical bearing and theclam shell clamp being suspended from the cylindrical bearing. In anexample, the apparatus has a torque tube comprising a first end and asecond end. The first end is coupled to the spherical bearing to supportthe torque tube from the upper region of the clamp housing member. Thetorque tube is configured from an off-set position from a center regionof rotation. The apparatus has a drive device coupled to the second endsuch that the drive device and the torque tube are configured to besubstantially free from a twisting action while under a load, e.g.,rotation, wind, other internal or external forces. Further details ofthe present examples can be found throughout the present specificationand more particularly below.

FIG. 1 is a simplified perspective view of a horizontal trackerapparatus configured with a plurality of solar modules according to anembodiment of the present invention. As shown, the present inventionprovides a tracker apparatus for solar modules. In an example, the solarmodules can be a silicon based solar module, a polysilicon based solarmodule, a concentrated solar module, or a thin film solar module,including cadmium telluride (CdTe), copper indium gallium selenide(CuIn1-xGaxSe2 or CIGS), which is a direct bandgap semiconductor usefulfor the manufacture of solar cells, among others. As shown, each of thesolar panels can be arranged in pairs, which form an array. Of course,there can be other variations. In an example, the first pier and thesecond pier are provided on a sloped surface, an irregular surface, or aflat surface. The first pier and the second pier are two of a pluralityof piers provided for the apparatus. In example, the apparatus has asolar module configured in a hanging position or a supporting position.

The tracker apparatus has a first pier comprising a first pivot deviceand a second pier comprising a drive mount. In an example, the firstpier is made of a solid or patterned metal structure, such as a widebeam flange or the like, as shown. In an example, each of the piers isinserted into the ground, and sealed, using cement or other attachmentmaterial. Each pier is provided in generally an upright position and inthe direction of gravity, although there can be variations. In anexample, each of the piers is spatially spaced along a region of theground, which may be flat or along a hillside or other structure,according to an embodiment. In an example, the first pillar comprises awide flange beam. In an example, the first pillar and the second pillarcan be off-set and reconfigurable.

In an example, the drive mount is capable for construction tolerances inat least three-axis, and is configured to a drive device. The drivedevice has an off-set clamp device coupled to a cylindrical bearingdevice coupled to a clamp member.

In an example, the apparatus has a cylindrical torque tube operablydisposed on the first pier and the second pier. In an example, thecylindrical torque tube comprises a one to ten inch diameter pipe madeof Hollow Structure Steel (HSS) steel. The cylindrical torque tubecomprises a first end and a second end, and a notch. The notch is one ofa plurality of notches spatially disposed along a length of thecylindrical torque tube.

In an example, the apparatus has a clamp configured around an annularportion of the cylindrical torque tube and mate with the notch toprevent movement of the clamp. The clamp comprises a support regionconfigured to support a portion of a solar module. The clamp comprises apin configured with the notch. The apparatus also has a rail configuredto the clamp. The rail comprises a thread region configured to hold abolt, which is adapted to screw into the thread and bottom out against aportion of cylindrical torque tube such that the clamp is desirablytorqued against the cylindrical torque tube. The apparatus has a solarmodule attached to the rail or other attachment device-shared moduleclaim or other devices. The cylindrical torque tube is one of aplurality of torque tubes configured in as a continuous structure andextends in length for 80 to 200 meters. Each pair of torque tubes isswage fitted together, and bolted for the configuration.

In an example, the apparatus also has a center of mass of along an axialdirection is matched with a pivot point of the drive device. The pivotpoint of the drive device is fixed in three dimensions while rotatingalong the center of mass. In an example, the off-set clamp comprises acrank device. The first pivot device comprises a spherical bearingconfigured a clam-shell clamp device to secure the first end to thecylindrical torque tube. In other examples, the drive device comprises aslew gear. The apparatus also has an overrun device configured with thefirst pivot device. The overrun device comprises a mechanical stop toallow the cylindrical torque tube to rotate about a desired range.Further details of the present tracker apparatus can be found throughoutthe present specification and more particularly below.

FIGS. 2 through 7 illustrate a method of assembling the horizontaltracker apparatus of FIG. 1. As shown, the method includes disposing afirst pier into a first ground structure. The method also includesdisposing a second pier into a second ground structure. Each of thepiers is one of a plurality of piers to be spatially disposed along aground structure for one row of solar modules configured to a trackerapparatus.

In an example, the method includes configuring a first pivot device onthe first pier.

In an example, the method includes configuring a drive mount on thesecond pier. In an example, the drive mount is capable for constructiontolerances in at least three-axis. In an example, the drive mount isconfigured to a drive device having an off-set clamp device coupled to acylindrical bearing device coupled to a clamp member.

In an example, the method includes assembling a cylindrical torque tubeand operably disposing on the first pier and the second pier cylindricaltorque tube. The cylindrical torque tube comprises a first end and asecond end, and a notch. In an example, the notch is one of a pluralityof notches spatially disposed along a length of the cylindrical torquetube.

In an example, the method includes assembling a plurality of clampsspatially disposed and configured around an annular portion of thecylindrical torque tube. Each of the plurality of clamps is configuredto mate with the notch to prevent movement of the clamp. In an example,the clamp comprises a support region configured to support a portion ofa solar module.

In an example, the method includes attaching a rail configured to eachof the clamps, the rail comprising a thread region configured to hold abolt. The bolt is adapted to screw into the thread and bottom outagainst a portion of cylindrical torque tube such that the clamp isdesirably torqued against the cylindrical torque tube.

In an example, the method includes attaching a solar module to the railor other attachment device. Further details of other examples can befound throughout the present specification and more particularly below.

FIG. 8 is a simplified perspective view of a pair of horizontal trackerapparatus configured together with a plurality of solar panels accordingto an embodiment of the present invention. As shown is a trackerapparatus for solar modules. The tracker apparatus has a first piercomprising a first pivot device, a second pier comprising a drive mount,and a third pier comprising a second pivot device. The second pier isbetween the first and third piers, as shown in an example. Of course,additional piers can be configured on each outer side of the first andthird piers.

In an example, the drive mount is capable for construction tolerances inat least three-axis, and is configured to a drive device. The drivedevice has an off-set clamp device coupled to a cylindrical bearingdevice coupled to a clamp member.

In an example, the apparatus has a cylindrical torque tube operablydisposed on the first pier and the second pier, and then on the thirdpier. In an example, the cylindrical torque tube comprises a first endand a second end, and a notch. The notch is one of a plurality ofnotches spatially disposed along a length of the cylindrical torquetube. The apparatus has a clamp configured around an annular portion ofthe cylindrical torque tube and mate with the notch to prevent movementof the clamp. The clamp comprises a support region configured to supporta portion of a solar module. In an example, the cylindrical torque tubeis configured to the drive device to rotate the cylindrical torque tubewhile each of the clamp members holds the tube in place. Further detailsof the present apparatus can be found throughout the presentspecification and more particularly below.

FIG. 9 is a simplified diagram of a plurality of horizontal trackerapparatus configured together according to an embodiment of the presentinvention. As shown is a solar tracker apparatus. The apparatus has acenter of mass with an adjustable hanger assembly configured with a clamshell clamp assembly on the adjustable hanger assembly and a cylindricaltorque tube comprising a plurality of torque tubes configured togetherin a continuous length from a first end to a second end such that thecenter of mass is aligned with a center of rotation of the cylindricaltorque tubes to reduce a load of a drive motor operably coupled to thecylindrical torque tube. In an example, the drive motor is operable tomove the torque tube about the center of rotation and is substantiallyfree from a load. The center of rotation is offset from a center of thecylindrical torque tube.

In an example, the invention provides a tracker apparatus comprising aplurality of torque tubes comprising a first torque tube coupled to asecond torque tube coupled to an Nth torque tube, whereupon N is aninteger greater than 2. Each pair of torque tubes is coupled to eachother free from any welds.

In an example, a single drive motor can be coupled to a center region ofthe plurality of torque tubes to rotate the torque tube in a desirablemanner to allow each of the solar modules to track a direction ofelectromagnetic radiation from the sun.

In an example, each tracker apparatus comprises a torque tube coupled toan array of solar panels, as shown. Each of the tracker apparatus iscoupled to each other via the torque tube, and a pivot device. Eachtracker has a corresponding pair of piers, a torque tube, and one ormore pivot devices, as shown. Further details of each of these elementsare described in detail throughout the present specification.

FIG. 10 is a simplified diagram of an array of a plurality of horizontaltracker apparatus configured together according to an embodiment of thepresent invention. As shown are an array of horizontally configuredtracker devices to form a plurality of rows of tracker devices arrangedin a parallel manner. Each pair of rows of trackers has an avenue, whichallows for other applications. That is, row crops or other things can beprovided in the avenue, which extends along an entirety of eachhorizontal tracker row. In an example, the plurality of trackerapparatus are configured in an array within a geographic region. Each ofthe plurality of tracker apparatus is driven independently of each otherto cause each row to stow independently at a different or similar angle.Unlike conventional trackers, which often have mechanical device betweenthe rows, each of the avenues is continuous from one end to the otherend, as allows for a tractor or other vehicle to drive from one end tothe other end in a preferred example. Of course, there can be othervariations, modifications, and alternatives.

In an example, the apparatus is configured substantially free from anywelds during assembly, and can be assembled using conventional tools. Inan example, the torque tube is coupled to another torque tube via aswage device within a vicinity of the clam shall clamp member. In anexample, the torque tube is coupled to an elastomeric damper in line todampen torque movement to be substantially free from formation of aharmonic waveform along any portion of a plurality of solar panelsconfigured to the torque tube.

In an example, the apparatus further comprising a locking damper orrigid structure to configure a solar panel coupled to the torque tube ina fixed tilt position to prevent damage to stopper and lock into afoundation-in a position that is substantially free from fluttering inan environment with high movement of air. In an example, the lockingdamper fixes each of the plurality of solar modules in a desirable anglerelative to the direction of air or wind.

In an example, the apparatus has a controller apparatus configured in aninserter box provided in an underground region to protect the controllerapparatus. In an example, the inserter box is made of a suitablematerial, which is sealed and/or environmentally suitable to protect thecontroller apparatus.

In operation, the apparatus has a drive device to linearly actuate thetorque tube to allow for desirable positions of each of the solarmodules relative to incident electromagnetic radiation. In an example,an electrical connection and source (e.g., 120V, 60 Hz, 240V) is coupledto a drive device. Of course, there can be variations.

FIG. 11 is a simplified diagram of a clamp assembly for the horizontaltracker of FIG. 1 according to an embodiment of the present invention.As shown, the clamp assembly has a clamp housing member configured in aupright direction, which is a direction away from a direction ofgravity. In an example, the clamp housing member comprises a lowerregion and an upper region. The lower region is coupled to a pierstructure. The lower region has a thickness of material comprising boltopenings, which align to openings on an upper portion of the pierstructure. Locking nuts and bolts are configured to hold the lowerregion of the clamp housing to the pier structure in an upright manner.At least a pair of openings are provided in each of the lower region ofthe clamp housing and the pier structure, as shown.

In an example, the upper region comprises a spherical bearing device.The upper region has a tongue structure, which has an opening thathouses the spherical bearing between a pair of plates, which hold thebearing in place. In an example, the spherical bearing allows forrotational, and movement in each of the three axis directions within adesirable range. Each of the plates is disposed within a recessed regionon each side of the tongue structure. Each of the plates may include afastener to hold such plate in place within the recessed region.

In an example, clamp assembly has a clam shell clamp member coupled tothe spherical bearing and the clam shell clamp being suspended from thespherical bearing. That is, the clam shell clamp has a first side and asecond side. Each side has an upper region comprising an opening. A pinis inserted through each of the openings, while an opening of thespherical bearing is provided as a third suspension region between eachof the openings, as shown.

Each side of the clam shell is shaped to conform or couple to at leastone side of a portion of the torque tube, as shown. Each side has one ormore opens, which align to one or more openings on the portion of thetorque tube. A pin or bolt is inserted through each of the openings toclamp the clam shell clamp to the portion of the torque tube andsurround substantially an entirety of a peripheral region of the torquetube. The pin or bolt or pins or bolts also holds the torque tube in afixed position relative to the clam shell clamp to prevent the torquetube from slipping and/or twisting within the clam shell clamp. Ofcourse, there can be variations.

In an example, the spherical bearing allows for a constructiontolerance, tracker movement, and acts as a bonding path of leastresistance taking an electrical current to ground. The bonding pathoccurs from any of the modules, through the frame, to each of the clampassembly, to one or more piers, and then to ground.

In an example, a torque tube comprising a first end and a second end iscoupled to the spherical bearing to support the torque tube from theupper region of the clamp housing member. In an example, the torque tubeis configured from an off-set position from a center region of rotation.

In an example, a drive device, which will be described in more detailbelow, is coupled to the second end such that the drive device and thetorque tube are configured to be substantially free from a twistingaction while under a load.

In an example, the clam shell apparatus comprising a first memberoperably coupled to a second member to hold a torque tube in place. Inan example, the apparatus has a clamp housing operably coupled to theclam shell apparatus via a spherical bearing device such that thespherical bearing comprises an axis of rotation, which is different froma center of the torque tube.

FIGS. 12 through 14 are simplified diagrams illustrating a method forassembling the clamp assembly of FIG. 11. In an example, the presentmethod is for assembling a solar tracker apparatus. The method includesproviding a clamp housing member configured in a upright direction. Theclamp housing member comprises a lower region and an upper region. In anexample, the lower region is coupled to a pier structure. The upperregion comprises a spherical bearing device. In an example, the uprightdirection is away from a direction of gravity. In an example, the methodincludes coupling a first half clam shell clamp member and a second halfclam shell clamp member (collectively a clam shell clamp member) to thecylindrical bearing. The method also includes supporting a torque tubebetween the first half clam shell clamp and the second half clam shellclamp, each of which is coupled to the spherical bearing to support thetorque tube from the upper region of the clamp housing member, thetorque tube being configured from an off-set position from a centerregion of rotation.

In an example, the apparatus is configured substantially free from anywelds during assembly. In an example, the torque tube is coupled toanother torque tube via a swage device within a vicinity of the clamshell clamp member. In an example, the torque tube is coupled to anelastomeric damper in line to dampen torque movement to be substantiallyfree from formation of a harmonic waveform along any portion of aplurality of solar panels configured to the torque tube.

In an example, the method includes coupling a pin member to the firsthalf clam shell clamp member, the second half clam shell clamp member,and the spherical bearing. In an example, the method includes coupling afirst member and a second member to sandwich the spherical bearing to atongue region of the upper region of the clamp housing member. In anexample, the spherical bearing is configured for rotation, and movementof the pin to pivot along a solid angle region. In an example, thehousing clamp member is a continuous structure made of cast or stampedor machined metal material. In an example, each of the first half clamshell member and the second half claim shell member is made of a solidcontinuous structure that is cast or stamped or machined metal material.In an example, the spherical bearing allows for a constructiontolerance, tracker movement, and acting as a bonding path of leastresistance taking an electrical current to ground. Further details ofthe present method and apparatus can be found throughout the presentspecification and more particularly below.

FIG. 15 is a simplified perspective diagram of a drive assemblyconfigured on a pier member according to an embodiment of the presentinvention. In an example, as shown, the solar tracker apparatuscomprises a drive device. The drive device is coupled to an electricmotor, which can be DC or AC. The drive device has a shaft, whichrotates around a rotational point, and drives each crank, which isdescribed below. The drive device is provided on a support or drivemount, which is configured on an upper region of a pier, which has beendescribed. The drive device is coupled to a crank coupled to the drivedevice and configured in an offset manner to a frame assembly, which hasa plurality of solar modules.

In an example, the drive device provides rotation to a continuous torquetube spatially disposed from a first region to a second region. Thedrive device has a drive line, which couples via a gear box to drive apair of cranks Each crank is coupled to each side of the drive device,which causes rotational movement of each crank.

In an example, the crank comprises a first crank coupled to a first sideof the drive device and a second crank coupled to a second side of thedrive device. In an example, the crank comprises a first crank coupledto a first side of the drive device and a second crank coupled to asecond side of the drive device. In an example, each crank has a flangehaving a plurality of bolt openings to couple to one side of the drivedevice. Each crank has an arm, which is normal to each flange, andcouples to cylindrical member that has one or more bolt openings. Theapparatus has a first torque tube coupled to the first crank via thecylindrical member and a second torque tube coupled to the second crankvia another cylindrical member. In an example, a first swage fitting iscoupling the first crank to the first torque tube and a second swagefitting is coupling the second crank to the second torque tube. One ormore bolts are inserted through the cylindrical members to secure aportion of the torque tube in place, and keep it free from rotation ortwisting within the cylindrical member, and lock it into place, asshown.

In an example, each of the cranks is made of a suitable metal materialthat may be cast, machined, or stamped. Each cylindrical member is madeof a suitable metal material to coupled to an end of the torque tube, asshown. A swage fitting can be provided to couple or connect the end ofthe torque tube to each cylindrical member as shown. Of course, therecan be variations. Further details of assembling the drive device can befound throughout the present specification, and more particularly below.

FIGS. 16 through 19 are simplified diagrams illustrating a method forassembling the drive assembly of FIG. 15. In an example, the methodincludes providing a drive device, as shown. In an example, the methodincludes coupling the drive device via a drive line or shaft to anelectric motor, which can be DC or AC. The method includes coupling thedrive device to a support or drive mount, which is configured on anupper region of a pier, which has been described. In an example, thepier comprising a plurality of support structures coupled to a drivedevice support. The drive device support having a first member coupledto the plurality of support structures, and a second member coupled tothe drive device.

In an example, the method includes coupling the drive device a crankcoupled to the drive device and configured in an offset manner to aframe assembly, which has a plurality of solar modules. In an example,the drive device has the drive line, which couples via a gear box todrive a pair of cranks Each crank is coupled to each side of the drivedevice, which causes rotational movement of each crank. In an example,the crank comprises a first crank coupled to a first side of the drivedevice and a second crank coupled to a second side of the drive device.In an example, the crank comprises a first crank coupled to a first sideof the drive device and a second crank coupled to a second side of thedrive device. In an example, each crank has a flange having a pluralityof bolt openings to couple to one side of the drive device. Each crankhas an arm, which is normal to each flange, and couples to cylindricalmember that has one or more bolt openings. The apparatus has a firsttorque tube coupled to the first crank via the cylindrical member and asecond torque tube coupled to the second crank via another cylindricalmember. In an example, a first swage fitting is coupling the first crankto the first torque tube and a second swage fitting is coupling thesecond crank to the second torque tube. One or more bolts are insertedthrough the cylindrical members to secure a portion of the torque tubein place, and keep it free from rotation or twisting within thecylindrical member, and lock it into place, as shown.

FIG. 20 is a simplified in-line view diagram illustrating a clampassembly separate and apart from a pier member according to anembodiment of the present invention. As shown, the clamp assembly has aclamp housing member configured in a upright direction, which is adirection away from a direction of gravity. In an example, the clamphousing member comprises a lower region and an upper region. The lowerregion is coupled to a pier structure. The lower region has a thicknessof material comprising bolt openings, which align to openings on anupper portion of the pier structure. Locking nuts and bolts areconfigured to hold the lower region of the clamp housing to the pierstructure in an upright manner. At least a pair of openings are providedin each of the lower region of the clamp housing and the pier structure,as shown. Each of the openings in the lower region of the clamp housingis configured as a slot to allow for adjustment in a direction normal tothe direction of the length of the pier structure. Each of the openingsin the pier structure is configured as an elongated slot in thedirection of the length of the pier structure to allow for adjustment inthe same direction. Of course, there can be variations, where thedirections of the slots are exchanged and/or combined.

In an example, the upper region comprises a spherical bearing device.The upper region has a tongue structure, which has an opening thathouses the spherical bearing between a pair of plates, which hold thebearing in place. In an example, the spherical bearing allows forrotational, and movement in each of the three axis directions within adesirable range. Each of the plates is disposed within a recessed regionon each side of the tongue structure. Each of the plates may include afastener to hold such plate in place within the recessed region.

In an example, the clamp housing has a pair of openings and lower regionthat is designed like a heart like shape and a tongue region, whichsupports the spherical bearing assembly, as shown. Each lobe of theheart like shape acts as a stop for movement of the torque tube in alateral rotational movement in either direction depending upon thespatial orientation of the lobe. Further details of the clamp housingcan be found further below.

In an example, clamp assembly has a clam shell clamp member coupled tothe spherical bearing and the clam shell clamp being suspended from thespherical bearing. That is, the clam shell clamp has a first side and asecond side. Each side has an upper region comprising an opening. A pinis inserted through each of the openings, while an opening of thespherical bearing is provided as a third suspension region between eachof the openings, as shown.

Each side of the clam shell is shaped to conform or couple to at leastone side of a portion of the torque tube, as shown. Each side has one ormore opens, which align to one or more openings on the portion of thetorque tube. A pin or bolt is inserted through each of the openings toclamp the clam shell clamp to the portion of the torque tube andsurround substantially an entirety of a peripheral region of the torquetube. The pin or bolt or pins or bolts also holds the torque tube in afixed position relative to the clam shell clamp to prevent the torquetube from slipping and/or twisting within the clam shell clamp. Ofcourse, there can be variations.

In an example, the spherical bearing allows for a constructiontolerance, tracker movement, and acts as a bonding path of leastresistance taking an electrical current to ground. The bonding pathoccurs from any of the modules, through the frame, to each of the clampassembly, to one or more piers, and then to ground.

In an example, the clam shell apparatus comprising a first memberoperably coupled to a second member to hold a torque tube in place. Inan example, the apparatus has a clamp housing operably coupled to theclam shell apparatus via a spherical bearing device such that thespherical bearing comprises an axis of rotation, which is different froma center of the torque tube.

FIG. 21 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member according to an embodiment of thepresent invention. As shown, a pair of nuts and bolts holds the pierstructure to the clamp housing along the dotted line.

FIG. 22 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member in a first orientation according to anembodiment of the present invention. As shown, the clamp housing can beoff-set in a vertical and lateral manner using the slots in each of thepier and housing structure facing the in-line view of the torque tube.

FIG. 23 is a simplified in-line view diagram illustrating a clampassembly coupled to a pier member in a second orientation according toan embodiment of the present invention. As shown, the clamp housing canbe adjusted in a rotational manner (in either direction) using the sameslots in each of the pier and housing structures facing the in-line viewof the torque tube.

FIG. 24 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a first orientation according to anembodiment of the present invention. As shown, the housing and pierstructure, along with the torque tube, are arranged in a normalorientation using the pins configuring the torque tube to the clam shellclamp member. As shown, the clamp member has an elongated opening toallow each of the pins to be adjusted in place, which allows therelationship of the clamp and torque tube to be adjusted.

FIG. 25 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a second orientation according to anembodiment of the present invention. As shown, the torque tube isshifted in an in-line direction (either way) using the slots in theclamp, while the torque tube has a smaller opening for the pin, whichdoes not allow for any adjustment, in an example.

FIG. 26 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a third orientation according to anembodiment of the present invention. As shown, the torque tube can berotated or adjusted relative to the direction of the length of the pierusing the movement of the spherical bearing assembly, explained andshown. As shown, the torque tube is parallel to the direction of gravityin an example.

FIG. 27 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a fourth orientation according to anembodiment of the present invention. As shown, the torque tube can berotated or adjusted relative to the direction of the length of the pierusing the movement of the spherical bearing assembly, explained andshown. As shown, the torque tube is not parallel to the direction ofgravity in an example.

FIG. 28 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a fifth orientation according to anembodiment of the present invention. As shown, the torque tube, housing,and clamp are aligned in this example.

FIG. 29 is a simplified side view diagram illustrating a clamp assemblycoupled to a pier member in a sixth orientation according to anembodiment of the present invention. As shown, the torque tube, housing,and clamp are aligned in this example. However, the position of thespherical bearing to pin has shifted in one direction by sliding the pinin the same direction, although the pin can be slid in the otheropposite direction in other examples. In this example, pin to clamparrangement can be moved along the pin from one spatial region toanother spatial region.

FIGS. 30 through 32 illustrate an in-line view of the clamp assembly andthe drive assembly in multiple configurations according to embodimentsof the present invention. As shown, the crank is in a lower position,which allows for the torque tube to be at its lowest position in anexample. As the drive device moves the crank, the torque tube swingsfrom the lowest position to an elevated position in a radial manneralong a first direction or an elevated position in a radial manner alonga second direction, as shown. As the torque tube rotates, the pluralityof solar panels fixed to the torque tube also rotate along a path from afirst spatial region to a second spatial region. As shown, each of theinner regions of the lobes acts as a stop for the torque tube or anoverride for the torque tube. Of course, there can be other variations.

FIG. 33 is a side view diagram of the tracker apparatus according to anembodiment of the present invention. As shown is a side view diagram ofthe torque tube, solar panels with frames, and clamp housing andstructure.

FIGS. 34 and 35 are simplified side view diagrams of a torque tubeaccording to an embodiment of the present invention. As shown, each ofthe torque tubes has a plurality of openings on each end for affixing toeither the clamp or drive device cylinder. Each of the torque tubes alsohas a plurality of openings for clamps configured to hold the tube to aframe coupled to the plurality of solar modules.

FIGS. 36, 37, and 38 are simplified perspective-view, side view, andfront view diagrams of a clamp member or half clam shell memberaccording to an embodiment of the present invention. As shown are theclam shell members, including pin opening to be coupled to the sphericalbearing, and a plurality of slots for bolts to hold the torque tube inplace and for adjustment.

FIGS. 39 and 40 are simplified perspective-view and side view diagramsof a clamp housing according to an embodiment of the present invention.As shown is the clamp housing configured as a heart like shape, withtongue. The tongue has a recessed region, and an opening or slot for thespherical bearing. The housing also has a member to be coupled to thepier structure.

FIGS. 41, 42, 43, and 44 are simplified diagrams of component(s) for aU-bolt member according to an embodiment of the present invention. Asshown is a U-bolt member and a pair of nuts to secure the U-bolt. Thecomponents also includes an upper clamp with a protrusion to be coupledto a notch or opening in the torque tube to present any movement betweenthe torque tube and U-bolt member. That is, the protrusion acts as astop to hold the U-bolt in place.

FIGS. 45, 46, and 47 are simplified diagrams illustrating a method ofconfiguring a U-bolt member to a torque tube according to an embodimentof the present invention. As shown are U-bolt coupled to a periphery ofthe torque tube. The clamp member including protrusion, which has anthinner portion and thicker portion, coupled to a notch in the torquetube. A pair of bolts fastens and secures the clamp member and U-bolt inplace to hold the frame structure, which couples to the plurality ofsolar modules.

FIGS. 48 and 49 illustrate various views of a tracker apparatusaccording to an embodiment of the present invention. As shown, thetorque tube and tracker apparatus are in a normal rest position.

FIGS. 50 and 51 illustrate views of a tracker apparatus according to anembodiment of the present invention. As shown, a lateral force isprovided against a direction normal to the length of the torque tube,which causes one end of the torque tube to move in the lateraldirection, while the other end remains fixed in an example.

FIGS. 52 and 53 illustrate an illustration of a torque tube according toan embodiment of the present invention. As shown, the torque tuberotates and swings in a radial manner upon being subjected to thelateral force, in an example. The torque tube stops against an innerside of one of the lobes of the clamp housing.

FIG. 54 is a front view diagram of a clamp assembly according to anexample of the present invention. As shown is a front view of a solartracker apparatus, and in particular a clamp assembly configured for atorque tube. In an example, the clamp assembly has a support structureconfigured as a frame having configured by a first anchoring region anda second anchoring region. As shown, the first anchoring region iscoupled to a pier support using a nut and bolt fastener. The secondanchoring region is coupled to a pier support using a nut and boltfastener. In an example, the frame structure is shaped as a loop that issymmetric and can also be non-symmetric in other examples. As shown, thesupport structure being configured from a thickness of metal material,such as high grade steel or other metal material with sufficientstrength. In an example, the support structure is stamped from thethickness of metal material. In an example, the support structure isconfigured from a stamped steel comprising a Q345 steel or othersuitable material. In an example, the support structure being configuredin an upright manner, and has a major plane region configured within theframe structure. As shown, the major plane region has an opening toallow the torque tube and related support members to move within theopening.

In an example, the torque tube is coupled to a pivot device configuredon the support structure. In an example, the torque tube suspending onthe pivot device and aligned within the opening of the support andconfigured to be normal to the plane region. In an example, the torquetube is configured on the pivot device to move about an arc in a firstdirection or in a second direction such that the first direction is in adirection opposite to the second direction. As mentioned, the supportstructure comprises the frame configured with the opening. As shown, theframe has a first stop region within a first inner region of the frameand a second stop region within a second inner region of the frame andconfigured to allow the torque tube to swing in a first direction withinthe opening and stop against the first stop region and swing in a seconddirection within the opening and stop against the second stop region. Inan example, the first stop region comprises a first flat region and thesecond stop region comprises a second flat region such that the firstflat region and the second flat region are coupled to each other via acontinuous length of metal material having a predefined width configuredas a portion of the frame.

In an example, (not shown), the assembly is coupled to a drive deviceconfigured to cause the torque tube to swing in the first direction andswing in the second direction. In an example, the pivot device isconfigured to allow the torque tube to move about an arc direction,while being fixed in other spatial domains. In an example, the pivotdevice comprises a pin structure configured in a sleeve or bearingassembly that is coupled to the frame structure.

FIG. 55 is a front view diagram of a clamp assembly in a stop positionaccording to an example of the present invention. As shown, the framehaving a first stop region within a first inner region of the frame anda second stop region within a second inner region of the frame andconfigured to allow the torque tube to swing in a first direction withinthe opening and stop against the first stop region and swing in a seconddirection within the opening and stop against the second stop region;and further comprising a drive device configured to cause the torquetube to swing in the first direction and swing in the second direction.

FIGS. 55A, 55B, 55C, 55D, and 55E illustrates various views of the clampassembly including a perspective view in a central position, aperspective view in a first stop position, a perspective view in asecond stop position, a side-view, and a top view in examples of thepresent invention. As shown, the pivot device comprises a pin structureconfigured in a sleeve or bearing assembly. In an example, the pivotdevice comprising a first U-bolt clamp and a second U-bolt clampcoupling a first portion of the torque tube and a second portion of thetorque tube, respectively. In an example, the pin structure is couplingthe first U-bolt clamp and the second U-bolt clamp through a pair ofopenings, and is configured normal to a major plane of each U-boltclamp. In an example, the pin, which is between each of the U-bolts, isconfigured to the sleeve or bearing assembly, which is coupled to aportion of the frame structure, to allow the torque tube to pivot aboutthe pin structure while the first U-bolt clamp and the second U-boltclamp firmly engage with the first portion of the torque tube and thesecond portion of the torque tube. As shown, the pin structure is fixedto the U-bolt claims using the pair of openings, and a key placed oneach side of the pine structure to prevent the pin structure to slideeither direction outside of the U-bolt clamp. As also shown, the bearingor sleeve assembly is bolted or fixed to the frame structure.

FIG. 56 is a perspective view of a frame structure to be configured forthe clamp assembly according to an example of the present invention. Asshown, the frame structure is configured as the loop with an openregion. As shown, the open region is symmetric in shape. Two anchorregions, including flats each of which is fitted with a slot to allowthe frame structure to be moved either way for adjustment purposes.

FIG. 57 illustrates a top view diagram, a front view diagram, and a sideview diagram of the frame structure to be configured for the clampassembly according to an example of the present invention. As shown, thetop view (as shown on the upper portion of the drawings) illustrates amember with constant width, while there can be variations. The frontview shows the open region configured within the loop structure orframe, and anchor regions, which have flats. The side view is also shown(along right hand side of drawings). Further details of the presentstructures can be found throughout the present specification and moreparticularly below.

FIG. 58 illustrates a top view diagram, a front-view diagram, and a sideview diagram of a U-bolt configured on a torque tube for a solar panelbracket (or frame structure) according to an example of the presentinvention. As shown, the top view (top portion of drawings) shows aclamp support with saddle region configured to the outer portion (notshown) of a portion of the torque tube. As shown, the saddle region iscoupled intimately with the portion of the torque tube. A flat regionincluding a pair of openings on each end serve as a bracket forattachment of a solar panel or panels in an example. As shown in thebottom left hand side, the front view has a clamping U-bolt coupling aportion of the torque tube and is configured to the clamp support. Asshown on the right hand side, the side view shows a leg or bolt of aU-bolt configured on one side of the torque tube and coupled to theclamp support. The other side has a similar configuration, including legor bolt of the U-bolt and torque tube.

FIG. 59 illustrates a front view diagram of the U-bolt configured to atorque tube for a solar panel bracket according to an example of thepresent invention. In an example, the clamp support member comprising afirst end and a second end and has a length in between the first end andthe second end. A width is also included. In an example, the clampsupport member being configured a saddle region having a first openingand a second opening and a inner opening such that a first leg of aU-bolt is inserted into the first opening and a second leg of the U-boltis inserted into the second opening while a clamp member is positionedto hold the U-bolt in place to secure a portion of the torque tube to anopposite side of the saddle region while the clamp member is in intimatecontact with the inner opening using a male portion provided within theinner opening to fit the male portion within the inner opening.

FIG. 60 illustrate a perspective view of a support member for the U-boltconfigured to a torque tube for a solar panel bracket according to anexample of the present invention. In an example as shown, the supportmember the first end and the second end and has the length in betweenthe first end and the second end. The width is also included. In anexample, the clamp support member has a saddle region having a firstopening and a second opening and a inner opening such that a first legof a U-bolt is inserted into the first opening and a second leg of theU-bolt is inserted into the second opening while a clamp member ispositioned to hold the U-bolt in place to secure a portion of the torquetube to an opposite side of the saddle region while the clamp member isin intimate contact with the inner opening using a male portion providedwithin the inner opening to fit the male portion within the inneropening.

FIG. 61 is a perspective view of a clamp assembly according to anexample of the present invention. As shown is a perspective view of asolar tracker apparatus, and in particular a clamp assembly configuredfor a torque tube. In an example, the clamp assembly has a supportstructure configured as a frame having configured by a first anchoringregion and a second anchoring region. The frame also has a butterflyshape or heart shape configured with a pair of lobes configured about arecessed region, which is for supporting a pin structure. As shown, thefirst anchoring region is coupled to a pier support using a nut and boltfastener. The second anchoring region is coupled to a pier support usinga nut and bolt fastener. In an example, the frame structure is shaped asa pair of loops that are symmetric and can also be non-symmetric inother examples. As shown, the support structure being configured from athickness of metal material, such as high grade steel or other metalmaterial with sufficient strength. In an example, the support structureis stamped from the thickness of metal material. In an example, thesupport structure is configured from a stamped steel comprising a Q345steel or other suitable material. In an example, the support structurebeing configured in an upright manner, and has a major plane regionconfigured within the frame structure. As shown, the major plane regionhas an opening to allow the torque tube and related support members tomove within the opening.

In an example, the torque tube is coupled to a pivot device configuredon the support structure, and in particular the recessed region. In anexample, the torque tube suspending on the pivot device and alignedwithin the opening of the support and configured to be normal to theplane region. In an example, the torque tube is configured on the pivotdevice to move about an arc in a first direction or in a seconddirection such that the first direction is in a direction opposite tothe second direction. As mentioned, the support structure comprises theframe configured with the opening. As shown, the frame has a first stopregion within a first inner region of the frame and a second stop regionwithin a second inner region of the frame and configured to allow thetorque tube to swing in a first direction within the opening and stopagainst the first stop region and swing in a second direction within theopening and stop against the second stop region. In an example, thefirst stop region comprises a first flat region and the second stopregion comprises a second flat region such that the first flat regionand the second flat region are coupled to each other via a continuouslength of metal material having a predefined width configured as aportion of the frame.

In an example, (not shown), the assembly is coupled to a drive deviceconfigured to cause the torque tube to swing in the first direction andswing in the second direction. In an example, the pivot device isconfigured to allow the torque tube to move about an arc direction,while being fixed in other spatial domains. In an example, the pivotdevice comprises a pin structure configured in a sleeve or bearingassembly that is coupled to the frame structure.

FIG. 62 is a top view diagram of a clamp assembly according to anexample of the present invention. As shown, the pivot device comprises apin structure configured in a sleeve or bearing assembly, which is fixedon the recessed region (not shown). In an example, the pivot devicecomprising a first U-bolt clamp and a second U-bolt clamp coupling afirst portion of the torque tube and a second portion of the torquetube, respectively. In an example, the pin structure is coupling thefirst U-bolt clamp and the second U-bolt clamp through a pair ofopenings, and is configured normal to a major plane of each U-boltclamp. In an example, the pin, which is between each of the U-bolts, isconfigured to the sleeve or bearing assembly, which is coupled to aportion of the frame structure, to allow the torque tube to pivot aboutthe pin structure while the first U-bolt clamp and the second U-boltclamp firmly engage with the first portion of the torque tube and thesecond portion of the torque tube. As shown, the pin structure is fixedto the U-bolt claims using the pair of openings, and a key placed oneach side of the pine structure to prevent the pin structure to slideeither direction outside of the U-bolt clamp. As also shown, the bearingor sleeve assembly is bolted or fixed to the frame structure. A pair ofspacers can be configured on each side of the recessed regions tomaintain the spacing of the pair of U-bolt clamps.

FIG. 63 is a front view diagram of a clamp assembly according to anexample of the present invention. FIG. 64 is a side view diagram of aclamp assembly according to an example of the present invention.

FIG. 65 illustrates a top view diagram of a frame structure to beconfigured for the clamp assembly according to an example of the presentinvention. FIG. 66 illustrates a front view diagram of a frame structureto be configured for the clamp assembly according to an example of thepresent invention. FIG. 67 illustrates a side view diagram of a framestructure to be configured for the clamp assembly according to anexample of the present invention. FIG. 68 is a perspective view of aframe structure to be configured for the clamp assembly according to anexample of the present invention.

FIG. 69 is a perspective view of a claim assembly on a pier structureaccording to an example of the present invention. FIG. 70 is a top viewdiagram of a clamp assembly on a pier structure according to an exampleof the present invention. FIG. 71 is a front view diagram of a clampassembly on a pier structure according to an example of the presentinvention. FIG. 72 is a side view diagram of a clamp assembly on a pierstructure according to an example of the present invention. As shown,the clamp assembly can be moved about in various directions usingslotted openings on each of the anchor structures or support members. Ofcourse, there can be other variations, modifications, and alternatives.

In an example, the present parts and elements can be made of suitablematerial, such as steel, aluminum, or other alloys. Additionally, suchsteel and/or alloys and/or aluminum can be cast, stamped, or welded, orcombinations thereof. Of course, there can be other variations,modifications, and alternatives. In an example, the drive motor isoperable to move the torque tube about a center of rotation and issubstantially free from a load. In an example, the drive motor moves thetorque tube about the center of rotation at substantially a same forcefrom a first radial position to a second radial position.

As used herein, the terms “first” “second” “third” or “n” are used in amanner that should be broadly interpreted, and do not necessarily implyorder. In an example, the terms can also be used to imply order, or canbe used to imply a similar or same step and/or element. Of course, therecan be other variations, modifications, and alternatives.

In example of a technique that can be employed to shape the variouselements described is a hydro-forming process, which was originallyderived back in Sep. 8, 1959 under U.S. Pat. No. 2,902,962, which ishereby incorporated by reference (the '962 patent), including any andall other patents that have cited the subject '962 patent, titledMACHINES FOR SHAPING HOLLOW TUBULAR OBJECTS filed Jan. 7, 1955, by M. M.GARVIN. The '962 patent relates to a machine for shaping a hollow metaltubular blank in a mold or die, the blank being bulged to the contour ofthe cavity of the mold by supplying increasing volumes of liquid underpressure to the interior of the blank or work piece and supplying metalinto the portion of the blank within the cavity of the mold from anun-deformed portion of the blank to maintain wall thickness in thebulged portion of the blank. Of course, there can be other variations,modifications, and alternatives.

It is understood that the examples and embodiments described herein arefor illustrative purposes only and that various modifications or changesin light thereof will be suggested to persons skilled in the art and areto be included within the spirit and purview of this application andscope of the appended claims.

What is claimed is:
 1. A clamp assembly for a solar module to beconfigured on a solar tracker system, the assembly comprising: athickness of rigid material; a planar surface region configured from afirst portion of the thickness of rigid material, the planar surfaceregion having a length and a width; a saddle region configured from asecond portion of the thickness of rigid material, the second portionbeing configured within an inner region of the planar surface region,the saddle region having a first surface and a second surface oppositeof the first surface, the second surface shaped as a circular arc to beconfigured over a peripheral portion of a cylindrical torque tubestructure; a first recessed region on a first side of the saddle regionand a second recessed region on a second side of the saddle region; afirst opening within the first recessed region; and a second openingwithin the second recessed region, wherein the first recessed region hasa slope configured from the saddle region to a first end of the planarsurface region; wherein the second recessed region has a slopeconfigured from the saddle region to a second end of the planar surfaceregion; wherein the planar surface region and the saddle region areformed from the thickness of rigid material; wherein the planar surfaceregion has a first part disposed on a first side of the saddle region,and a second part disposed on a second side of the saddle region, thefirst and second sides of the saddle region being opposing sides of awidth dimension of the saddle region; wherein the circular arc of thesaddle region is arranged to accept the cylindrical torque tubestructure when a longitudinal axis of the cylindrical torque tubestructure in oriented the width dimension; and the solar module iscoupled to the cylindrical torque tube.
 2. The assembly of claim 1wherein the saddle region comprises a key structure to be inserted intoa notch structure configured on the peripheral portion of thecylindrical torque tube structure such that the key structure is a maleportion to be inserted into a female portion of the notch structure tointimately connect the saddle region to the peripheral portion of thecylindrical torque tube structure.
 3. The assembly of claim 1 whereinthe first recessed region is a mirror image of the second recessedregion.
 4. The assembly of claim 1, wherein the saddle region comprisesa first wider region within a vicinity of the first recessed region, anda second wider region within a vicinity of the second recessed region.5. The assembly of claim 1 further comprising: a U-bolt configured on alower portion of the peripheral portion of the cylindrical torque tubestructure such that a first bolt protrudes through the first opening anda second bolt protrudes through the second opening, and a first fastenercoupled to the first bolt and a second fastener coupled to the secondbolt to secure the saddle region to the torque tube structure bysandwiching the torque tube structure between the second surface and abottom portion of the U-bolt.
 6. The assembly of claim 1, wherein thesaddle region comprises a first wider region within a vicinity of thefirst recessed region, and a second wider region within a vicinity ofthe second recessed region; wherein the first recessed region, thesaddle region, and the second recessed region are configured as an hourglass type shape when viewed from a spatial location normal to theplanar surface region.
 7. The assembly of claim 1 wherein the thicknessof rigid material comprises steel.
 8. The assembly of claim 1 furthercomprising a first border configured on a first edge of the planarsurface region and a second border configured on second edge of theplanar surface region.
 9. The assembly of claim 1 further comprising afirst border configured on a first edge of the planar surface region anda second border configured on second edge of the planar surface region;and further comprising a pair of first openings within a vicinity of afirst end of the planar surface region and a pair of second openingswithin a vicinity of a second end of the planar surface region.
 10. Aclamp assembly for a solar module to be configured on a solar trackersystem, the assembly comprising: a thickness of rigid material; asurface region configured from a first portion of the thickness of rigidmaterial, the surface region having a length and a width; a saddleregion configured from a second portion of the thickness of rigidmaterial, the second portion being configured within an inner region ofthe surface region, the saddle region having a first surface and asecond surface opposite of the first surface, the second surface shapedas a circular arc to be configured over a peripheral portion of acylindrical torque tube structure; wherein the planar surface region hasa first part disposed on a first side of the saddle region, and a secondpart disposed on a second side of the saddle region, the first andsecond sides of the saddle region being opposing sides of a widthdimension of the saddle region; wherein the circular arc of the saddleregion is arranged to accept the cylindrical torque tube structure whena longitudinal axis of the cylindrical torque tube structure in orientedthe width dimension; wherein the saddle region comprises a key structureto be inserted into a notch structure configured on the peripheralportion of the cylindrical torque tube structure such that the keystructure is a male portion to be inserted into a female portion of thenotch structure to intimately connect the saddle region to theperipheral portion of the cylindrical torque tube structure; a firstrecessed region on a first side of the saddle region and a secondrecessed region on a second side of the saddle region; and a firstopening within the first recessed region and a second opening within thesecond recessed region; wherein the first recessed region has a slopeconfigured from the saddle region to a first end of the surface region;wherein the second recessed region has a slope configured from thesaddle region to a second end of the surface region; and the solarmodule is coupled to the cylindrical torque tube.
 11. The assembly ofclaim 10 wherein the first recessed region, the saddle region, and thesecond recessed region are configured as an hour glass type shape whenviewed from a spatial location normal to the surface region; wherein thesurface region comprises a planar surface region; wherein the thicknessof rigid material comprises steel; a first border configured on a firstedge of the surface region and a second border configured on second edgeof the surface region; and wherein the surface region comprising theplanar surface region configured from the thickness of material extendsfrom a first outer end to a second outer end of the thickness ofmaterial.
 12. A clamp assembly for a solar module to be configured on asolar tracker system, the assembly comprising: a thickness of rigidmaterial; a planar surface region configured from a first portion of thethickness of rigid material, the planar surface region having a lengthand a width; a saddle region configured from a second portion of thethickness of rigid material, the second portion being configured withinan inner region of the planar surface region, the saddle region having afirst surface and a second surface opposite of the first surface, thesecond surface shaped as a circular arc to be configured over aperipheral portion of a cylindrical torque tube structure; a firstrecessed region on a first side of the saddle region and a secondrecessed region on a second side of the saddle region; a first openingwithin the first recessed region; and a second opening within the secondrecessed region, wherein the saddle region comprises a first widerregion within a vicinity of the first recessed region, and a secondwider region within a vicinity of the second recessed region; whereinthe planar surface region and the saddle region are formed from thethickness of rigid material; wherein the planar surface region has afirst part disposed on a first side of the saddle region, and a secondpart disposed on a second side of the saddle region, the first andsecond sides of the saddle region being opposing sides of a widthdimension of the saddle region; wherein the circular arc of the saddleregion is arranged to accept the cylindrical torque tube structure whena longitudinal axis of the cylindrical torque tube structure in orientedthe width dimension; and the solar module is coupled to the cylindricaltorque tube.
 13. A clamp assembly for a solar module to be configured ona solar tracker system, the assembly comprising: a thickness of rigidmaterial; a planar surface region configured from a first portion of thethickness of rigid material, the planar surface region having a lengthand a width; a saddle region configured from a second portion of thethickness of rigid material, the second portion being configured withinan inner region of the planar surface region, the saddle region having afirst surface and a second surface opposite of the first surface, thesecond surface shaped as a circular arc to be configured over aperipheral portion of a cylindrical torque tube structure; a firstrecessed region on a first side of the saddle region and a secondrecessed region on a second side of the saddle region; a first openingwithin the first recessed region; a second opening within the secondrecessed region; a U-bolt configured on a lower portion of theperipheral portion of the cylindrical torque tube structure such that afirst bolt protrudes through the first opening and a second boltprotrudes through the second opening; and a first fastener coupled tothe first bolt and a second fastener coupled to the second bolt tosecure the saddle region to the torque tube structure by sandwiching thetorque tube structure between the second surface and a bottom portion ofthe U-bolt; wherein the planar surface region and the saddle region areformed from the thickness of rigid material; wherein the planar surfaceregion has a first part disposed on a first side of the saddle region,and a second part disposed on a second side of the saddle region, thefirst and second sides of the saddle region being opposing sides of awidth dimension of the saddle region; wherein the circular arc of thesaddle region is arranged to accept the cylindrical torque tubestructure when a longitudinal axis of the cylindrical torque tubestructure in oriented the width dimension; and the solar module iscoupled to the cylindrical torque tube.
 14. A clamp assembly for a solarmodule to be configured on a solar tracker system, the assemblycomprising: a thickness of rigid material; a planar surface regionconfigured from a first portion of the thickness of rigid material, theplanar surface region having a length and a width; a saddle regionconfigured from a second portion of the thickness of rigid material, thesecond portion being configured within an inner region of the planarsurface region, the saddle region having a first surface and a secondsurface opposite of the first surface, the second surface shaped as acircular arc to be configured over a peripheral portion of a cylindricaltorque tube structure; a first recessed region on a first side of thesaddle region and a second recessed region on a second side of thesaddle region; a first opening within the first recessed region; asecond opening within the second recessed region; and wherein the saddleregion comprises a first wider region within a vicinity of the firstrecessed region, and a second wider region within a vicinity of thesecond recessed region; wherein the first recessed region, the saddleregion, and the second recessed region are configured as an hour glasstype shape when viewed from a spatial location normal to the planarsurface region; wherein the planar surface region and the saddle regionare formed from the thickness of rigid material; wherein the planarsurface region has a first part disposed on a first side of the saddleregion, and a second part disposed on a second side of the saddleregion, the first and second sides of the saddle region being opposingsides of a width dimension of the saddle region; wherein the circulararc of the saddle region is arranged to accept the cylindrical torquetube structure when a longitudinal axis of the cylindrical torque tubestructure in oriented the width dimension; and the solar module iscoupled to the cylindrical torque tube.